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HeatStation™ CONDENSING WATER BOILER

 

 

34-1161  05/17

 

BOILER INSTALLATION 

3.1  Checking Equipment Before You Install 

  Inspect the unit completely upon receipt from the freight carrier before signing the bill of lading. Inspect the appliance 

and all accompanying parts for signs of impact or mishandling. Verify the total number of pieces shown on packing 
slips with those actually received. Contact the freight carrier immediately if any damage or shortage is detected. 

  Check the data decal on the appliance. Be sure the electrical, water and gas supply is adequate for the installation. 

  Carefully remove all side and top shipping supports and bracing. If possible, do not remove the wooden base/skid 

assembly until the  product has been moved to its final  location for installation  and operation (see: Handling and 
Locating the boiler). 

 

3.2  Codes

 

The equipment must be installed in accordance with those installation regulations in force in the local area where the 
installation is to be made. Authorities having jurisdiction must be consulted before installation is made. In the absence 
of such requirements, the installation must be in accordance with the instructions in this manual, appliance markings 
and  supplemental  instructions  and  in  compliance  with  the  latest  edition  of  the  National  Fuel  Gas  Code,  ANSI 
Z223.1/NFPA 54. Where required by the Canadian authority  having jurisdiction, the equipment must  be installed in 
accordance  with  the  latest  edition  of  the  CAN/CSA  B149.1-10  Natural  Gas  and  Propane  Installation  Code  and 
applicable  Provincial  Regulations.  All  appliances  conform  to  the  current  edition  of  the  ASME  Boiler  and  Pressure 
Vessel Code, Section IV, Part HLW. 

 

3.3  Electrical Requirements

 

 

See  appliance  rating  decal  for  electrical  service  requirements.  The  appliance  must  be  electrically  supplied  and 
grounded  in  accordance  with  the  requirements  of  the  authority  having  jurisdiction  or,  in  the  absence  of  such 
requirements,  with  the  latest  edition  of  the  National  Electrical  Code  ANSI/NFPA  No.  70.  In  Canada,  the  electrical 
service must conform to local electrical codes and/or CSA C22.1, Canadian Electrical Code, Part 1. 

 

All wiring between the unit and field installed devices must be made with stranded copper wire. 

 

Line voltage wire exterior to the appliance must be enclosed in approved conduit or approved metal clad cable. 

 

To avoid serious damage, 

DO NOT

 energize the unit until the system and appliance is full of water. 

Utiliser du fil de cuivre de la taille appropriée pour le service électrique entrant. Les dommages résultant de l'utilisation 
de fil d'aluminium seront exclus du champ d'application de la garantie de cet appareil. 

 

3.4  Handling and Locating the Boiler 

WARNING:  Use  industry  standard  safe  rigging  methods,  such  as  strapping  around  the  boiler  base/skid 
assembly  and  using  spreader  bars,

 

when  attempting  to  lift  or  move  this product.  Failure  to  follow  industry 

standard safe rigging methods can result in property damage, serious injury or death.

 

1.  The boiler must be located indoors. 

2.  This boiler can be installed directly on a combustible floor. 

3.  The boiler must not be installed on carpeting. 

4.  Locate the boiler in an area that is not exposed to freezing temperatures. 

5.  The boiler should be installed on a level 4

"

 housekeeping pad for proper drainage of condensate.  

6.  Locate the boiler near a floor drain.  Locate the unit so if  the heat exchanger or water connections  should leak, 

water  damage  will  not  occur  to  the  adjacent  area  or  to  lower  floors  of  the  building.  When  such  locations  are 
unavoidable, install an adequately drained metal drain pan underneath  the  boiler. 

The manufacturer’s warranty 

does not cover water damage. 

7.  Protect  associated  electrical  components  and  electrical  connections  from  water  (dripping,  spraying,  rain,  etc.) 

during appliance operation and service. 

8.  Locate the boiler where the vent and air intake piping, when installed, will remain within the maximum equivalent 

lengths allowed. See Venting section for details. 

3.5  Clearances To Combustible Surfaces 

The minimum clearance to combustible material is 0

"

 from the front and zero clearance (0

"

) from the top, sides and 

Summary of Contents for HeatStation HS 1000

Page 1: ...OLLOW THE INFORMATION IN THIS MANUAL AND ALL OTHER PROVIDED INSTRUCTIONS LABELS AND MARKINGS BEFORE INSTALLING OPERATING OR SERVICING THIS UNIT TO THE INSTALLER After installation these instructions m...

Page 2: ...Appliance Isolation during Gas Supply Piping Pressure Test 6 7 Gas Connection 7 Combustion and Ventilation Air 7 1 Equipment Located in Confined Spaces 7 2 Maximum Allowed Remote Combustion Air Inlet...

Page 3: ...iagnostic Codes Flashes 11 3 Replacing the Fuse 11 4 Self Check Control Failure 11 5 System Safety Checks 11 6 Flame Current Measurements 11 7 Non Volatile Lockout Manual Reset 11 8 ID Card 12 Remote...

Page 4: ...his product contains or may come to contain materials that have been identified as carcinogenic or possibly carcinogenic to humans Before installing servicing or removing this product read and follow...

Page 5: ...ing controls Use NIOSH MSHA approved respirators as required see MSDS Wear long sleeved loose fitting clothing eye protection and gloves FIRST AID MEASURES If any of the irritations listed persists se...

Page 6: ...HeatStation CONDENSING WATER BOILER 6 34 1161 05 17 2 PRODUCT DESCRIPTIONS Component Controls and Connection Locations Locations May Vary Dimensional information for HS 1000 HS 1250 and HS 1500...

Page 7: ...HeatStation CONDENSING WATER BOILER 7 34 1161 05 17 Dimensional information for HS 1750 and HS 2000...

Page 8: ...f the National Electrical Code ANSI NFPA No 70 In Canada the electrical service must conform to local electrical codes and or CSA C22 1 Canadian Electrical Code Part 1 All wiring between the unit and...

Page 9: ...odes or regulations that may apply are the National Electric Code State Regional National drain water and flue emissions regulations the National Fuel Gas Code Building Construction and Safety Codes t...

Page 10: ...LER 10 34 1161 05 17 IMPORTANT Do not use the plumbing connected to the appliance as a ground for welding or any other purpose Example of a Single Boiler Primary Only Installation Example of a Multi B...

Page 11: ...HeatStation CONDENSING WATER BOILER 11 34 1161 05 17 Example of a Single Boiler Primary Secondary Only Installation Example of a Multi Boiler Primary Secondary Only Installation...

Page 12: ...or the return sensor located in the lower for operation as needed As the HeatStation is shipped the controlling sensor is the supply sensor If return sensor control is preferred refer to Section 10 fo...

Page 13: ...trap assembly from the union downward and rotate the outlet vertically to maintain a three 3 inch distance from the hose connector to the floor IMPORTANT Do not rotate the trap U bend toward the ceil...

Page 14: ...ere the 3 threaded end cap can be removed to recharge the Neutralizer with crushed limestone a The CNS must be located such that condensate will flow downhill from the condensate trap outlet to the in...

Page 15: ...njury or death 6 3 Inlet Pressure Measure at the inlet pressure tap located at the main gas cock The inlet pressure must remain within the minimum and maximum values while the unit is at rest and whil...

Page 16: ...y piping connected to the appliance to isolate the burner and gas train from main supply gas in compliance with NFPA 54 National Fuel Gas Code and most local Codes 6 The gas system installer must clea...

Page 17: ...losure if communicating with the outdoors through horizontal ducts All Air From Inside The Building Follow the requirements of NFPA 54 National Fuel Gas Code ANSI Z223 1 section Indoor Combustion Air...

Page 18: ...rminal Duct Pipe 6 Duct 8 Duct 90 Elbow 20 feet 10 feet 90 Long Radius Elbow 12 feet 6 feet 45 Elbow 12 feet 6 feet The following remote air duct information is provided for use in design calculations...

Page 19: ...t combine remote air ducting of multiple appliances into a single remote air duct unless the combined remote air ducting system has been evaluated and designed by a specified duct design firm and the...

Page 20: ...n result in property damage personal injury or death 8 1 Vent Material Selection The HeatStation can safely use plastic venting in systems that use colder building return water throughout the year Hig...

Page 21: ...Length in Equivalent Feet Vent Size 6 All Models 8 Vent All Models 10 Vent All Models Max Equivalent Length 230 eq feet 340 eq feet 460 eq feet Vent pipe fittings reduce the maximum allowable vent le...

Page 22: ...rner of an L shaped structure 9 A vertical vent must exhaust outside the building at least 3 feet 0 91m above the point of the exit and at least 2 feet 0 61 m above the highest point of the roof withi...

Page 23: ...r tight seal 6 Clean and deburr all solid PVC pipe ends then trial assemble the entire vent system vent before joining with cement Mark the pipe and fittings to identify their locations then disassemb...

Page 24: ...lled it must be checked to confirm all joints in the vent system are air and water tight After the vent is assembled close the end of the vent with a taped plastic bag or some other temporary closure...

Page 25: ...ed to prevent it from lifting out of the drain under discharge pressure and must be routed to allow complete drainage of the valve and piping Do not plug the relief valve s or install a reducing coupl...

Page 26: ...ustable through a Touch Screen User Interface located in the front control panel The control is factory pre set at approximately 140 F Boiler Control Panel Section 10 1 in this manual for more informa...

Page 27: ...an RJ485 patch cable All communication between the PIM and control display as well as the power to the control display is through this cable Platform Ignition Module PIM ID Card Flame current test pi...

Page 28: ...system IGN The Hot Surface Igniter is hot and the gas valve has opened to attempt burner ignition 4 seconds BURN The Burner has ignited and the flame has been sensed WWSD The boiler is currently in Wa...

Page 29: ...the Target Temperature that it is currently trying to maintain at the control temperature sensor CNTL TEMP If there is no current requirement for heat the Target Temperature is displayed as SUPPLY Di...

Page 30: ...or the outdoor temperature and automatically adjust the Target setpoint up and down in order to provide the optimum system temperature based on changes in the outdoor temperature See Section 10 13 for...

Page 31: ...It is recommended that Isolation valves should be configured for normally open power close operation 10 8 Selecting the Supply or Return Sensor for Single Boiler Primary Only Control A four switch Di...

Page 32: ...by first turning on the HEAT SCHD using the arrow buttons 2 There are four setback schedule types 24hr 5 2 5 11 and 7DAY The 24hr schedule is a daily schedule that will follow the same program every...

Page 33: ...trol of boiler operation is complete always return this parameter to the AUTO setting 2 The second setting is OFF This setting will stop all control function and prevent the burner from operating 3 Th...

Page 34: ...ture during the coldest weather can reduce up front system costs as well as improve the space heating comfort level When Outdoor Reset operation is desired there are additional control settings that n...

Page 35: ...to the PIM control terminal as illustrated below Connect Outdoor Sensor to the ORD and GND terminals Use 18 AWG or similar wire between control and sensor Do not run the wires parallel to telephone or...

Page 36: ...e MOD COM parameter set at 75 when the Master boiler reaches 75 burner modulation rate the EOS will enable boiler 2 and reduce the modulation rate to a minimum As the heat load increases the EOS will...

Page 37: ...but the correct state should be verified during setup MOD COND 50 to 100 For Parallel modulation this parameter will select the burner modulation percentage once reached will trigger the next boiler...

Page 38: ...the call for heat will be made and the burner will operate at the firing rate defined by the MIN MOD setting located in the SOURCE MENU 10 When the signal reaches 10 0Vdc the burner will operate at t...

Page 39: ...ystem 10 18 Using Tool Box Menu The TOOL BOX MENU contains several adjustable parameters as well as up to the 15 past alarm messages logged 1 The first screen in the Tool Box is for the ACCESS level T...

Page 40: ...ugh the gas valve If no mechanical cause can be found replace flame control 2 19 FLAME FAIL Flame failure indicates that during the burner ignition process the burner either failed to light or it did...

Page 41: ...fter ignition failure In this case the lockout may only be reset by the on board manual reset button or the remote reset input 11 8 ID Card Boil OUT Indicates a problem with the supply temperature sen...

Page 42: ...System L1 L2 Used for incoming 120VAC power supply connection Terminal L1 is the hot terminal Black and L2 is neutral White See the product catalog or specification document for circuit ampacity rati...

Page 43: ...ULATOR output on the component terminal strip provides a 120 Vac 0 5 amp pilot voltage to control a boiler water isolation valve Do not directly energize the valve actuator through these terminals The...

Page 44: ...mbined in a common probe body with the supply sensor located in the upper header The PIM compares the high limit temperature with the supply sensor temperature If the two temperatures are not the same...

Page 45: ...emperature of the controlling sensor is compared to the temperature control set point to determine when to begin firing in heating mode d The boiler remains in heating mode and with extended operation...

Page 46: ...upply in accordance with the Nameplate Rating Adequate uncontaminated indoor or outdoor combustion air Adequate Fuel Supply Adequate Boiler Water Supply 30 gpm min flow Exhaust Vent that complies with...

Page 47: ...he available gas type is not correct contact Rverside Hydronics for instructions CONFIRM THE SUPPLY GAS PRESSURE WARNING If you smell gas Do not try to light any appliance Do not try to touch any elec...

Page 48: ...t Proving failure message 3 Now open the manual shutoff gas valve at the burner Then push and release the MAIN RESET button on the front panel of the boiler to recover from the lockout condition If al...

Page 49: ...rner is firing the burner will shut down and recycle i Using the UP or DOWN arrow buttons adjust the firing rate from OFF to the minimum firing rate of 10 for Low Fire j If the CO2 levels at Low Fire...

Page 50: ...ME button for 3 seconds to display the SETUP Menu 2 Using the NEXT ITEM or ITEM BACK buttons navigate to the TOOLBOX menu then touch the ENTER button to display the ACCESS menu 3 Now press and hold th...

Page 51: ...or erratic ground Follow the Initial Startup instructions in Section 14 as the first step in any troubleshooting Verify that the system is powered and that the thermostat is calling for heat If the c...

Page 52: ...f blocked flue switch Check for voltage at the common side of blocked switch Check if switch tubing is connected on both ends Flow switch Indicated by Remote Equipment Proving failure message Verify p...

Page 53: ...r rating Low Voltage Fault 5 flashes Check the 24 VAC input voltage The voltage must be above 18 0 VAC Vent Temperature Fault 6 flashes Check for a blocked flue Check the vent sensor and connections H...

Page 54: ...X 310 MM 126852 126852 3 BURNER WORGAS 140 X 648 MM 125559 125559 125559 4 INTAKE AIR DUNGS WHIRLWIND 126864 126864 126864 4 INTAKE AIR DUNGS WHIRLWIND 126895 126895 5 ADAPTER FLEXIBLE RUBBER 6 X 5 12...

Page 55: ...EED 122346 122346 122346 122346 122346 11 SWITCH AIR PROVING CLEVELAND CONTROLS 111208 111208 111208 111208 111208 12 FLAME CONTROL PIM FENWAL 143623 143623 143623 143623 143623 13 TRANSFORMER STEP DO...

Page 56: ...K 1 1 2 X 7 57612 57612 7 NIPPLE BLACK 1 1 2 X 4 6057 6057 8 NIPPLE BLACK 1 X 2 6011 6011 6011 6011 6011 9 ELL BLACK 90DEG 6163 6163 6163 47330 47330 10 ELL BLACK 90DEG 6163 6163 6163 44699 44699 11 S...

Page 57: ...HeatStation CONDENSING WATER BOILER 57 34 1161 05 17 16 4 Component Wiring Details...

Page 58: ...or excessive gas A blocked heat exchanger can cause unsafe operation and will reduce efficiency To inspect and clean the heat exchanger a qualified service agent or installer should use the procedures...

Page 59: ...sure the flow of combustion and ventilation air is unobstructed to the appliance 9 When electrical controls are serviced or replaced label all connections as they are removed to know the proper place...

Page 60: ...7 Inspect burner and gas train components for wear or deterioration 8 Check the electronic ignition system for quick ignition and proper flame signal 9 Check gas safety shut off valves for proper oper...

Page 61: ...HeatStation CONDENSING WATER BOILER 61 34 1161 05 17...

Page 62: ...ter conditions or maintenance the warranty on the heat exchanger does not cover poor performance structural failure or leaking due to an excessive accumulation of scale MODEL NUMBER SERIAL NUMBER INST...

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